Dealer: Front CV Axle/Diff splines severely rusted

[Rambroh]

I just got a report from the dealer that says they “found front CV axle two differential spines severely rusted backlash worn out.”
Here are pictures. This looks like normal but I really don’t know. I do live near coast with salt air. What do you guys think? Is this an issue?

 

[Sascwatch]

I’ve seen lots of videos regarding this and the only fix is to replace the cv axles and stub (intermediate)shafts. I suppose the rust could eventually get bad enough that the splines rust out completely and you lose 4wd as the rusted out side would just spin.

I had a cv axle replaced on my 2020 due to clunking noises and a large amount of rust. Inside the stub (intermediate) shaft to cv axle is a small spring clip and that is all that holds the cv axle onto the stub shafts on each side. If rust were to build up it might make removal of a cv axle harder or nearly impossible overtime.

I currently have a clunking noise in my front end that is usually sway bar bushings, but after replacing them for a 4th time the clunk did not go away. I am suspecting the drivers side cv to stub shaft connection as it shows signs of rust like yours aswell as a ton more play than the passenger side.

There is no grease applied to these splines from the factory, nor is there a seal to keep water/salt brine out of the connection. Poorly designed in my opinion.

 

[Rambroh]

Is there any issue if I clean them up and spray undercoating in them?

 

[Scram1500]

Couldn't hurt, at the least soak it a few times on the outside with some kind of oil based spray like Seafoam

 

[kapinallinen2]

Is there any issue if I clean them up and spray undercoating in them?

Undercoating might dry up and prevent the splines from sliding.
When I replaced my passenger side bearing hub I took the CV shaft off, cleaned the splines and put bearing grease on them.

 

[Sascwatch]

Finally got some decent weather above freezing so I took a video of the play in both from cv axles. I also noticed the front diff itself moves a small amount, maybe it’s mounted in rubber bushings? Hard to tell with all the ice and snow under my truck.

Can’t post videos here, weird. Will upload elsewhere.

Any techs on here that can say whether this is normal or not? It’s a 3-4 hour drive to the nearest dealer.

 

[kapinallinen2]

Can’t post videos here, weird. Will upload elsewhere.

Never been able to.
Posting to you-tube like you did is the easiest.

 

[Wnghks701]

Finally got some decent weather above freezing so I took a video of the play in both from cv axles. I also noticed the front diff itself moves a small amount, maybe it’s mounted in rubber bushings? Hard to tell with all the ice and snow under my truck.

Can’t post videos here, weird. Will upload elsewhere.

Any techs on here that can say whether this is normal or not? It’s a 3-4 hour drive to the nearest dealer.

Not normal. I’ve heard that it’s pretty common in 5th gens front axle to be weak and the passenger side axle gets rusted on to the diff.

Mine does the same and makes clunky noise when I go over bumps. Especially from driver side. I have an appointment at the end of the month for mine to be looked by dealer

 

[HookedonRam]

Not normal. I’ve heard that it’s pretty common in 5th gens front axle to be weak and the passenger side axle gets rusted on to the diff.

Mine does the same and makes clunky noise when I go over bumps. Especially from driver side. I have an appointment at the end of the month for mine to be looked by dealer

I'm actually dealing with this right now. I have a case open with Ram. Dealership and Ram Cares both seem reluctant to do anything about it. I have 57k miles with powertrain warranty and Mopar Max Care.

 

[Wnghks701]

I'm actually dealing with this right now. I have a case open with Ram. Dealership and Ram Cares both seem reluctant to do anything about it. I have 57k miles with powertrain warranty and Mopar Max Care.

Let us know how it goes. I have 2019 with max care as well. Hoping they’ll cover

 

[HookedonRam]

Let us know how it goes. I have 2019 with max care as well. Hoping they’ll cover

I just talked to the dealership again today and they are basically telling me to go kick rocks.

 

[Cbty2050]

You concerned about the external rust on the cv shafts?

 

[HookedonRam]

You concerned about the external rust on the cv shafts?

No, the clunking noise coming from it.

 

[Cbty2050]

No, the clunking noise coming from it.

I couldn't see that in the video, I must have missed it.

 

[Wnghks701]

I just talked to the dealership again today and they are basically telling me to go kick rocks.

I was able to get an appointment sooner than original date. I’ll keep you posted on mine!

 

[1BADRAMLIMITED]

Not normal. I’ve heard that it’s pretty common in 5th gens front axle to be weak and the passenger side axle gets rusted on to the diff.

Mine does the same and makes clunky noise when I go over bumps. Especially from driver side. I have an appointment at the end of the month for mine to be looked by dealer

I’ve got the same issue 2019 limited 95k miles

 

[HookedonRam]

I was able to get an appointment sooner than original date. I’ll keep you posted on mine!

Keep us posted, please, and good luck!

 

[Wnghks701]

Keep us posted, please, and good luck!

Thanks, appointment is on Monday.

The parts doesn’t look expensive. If dealership tells me to go pound sand, I’ll probably knock it out over a weekend or take it to an independent shop.

 

[HookedonRam]

Thanks, appointment is on Monday.

The parts doesn’t look expensive. If dealership tells me to go pound sand, I’ll probably knock it out over a weekend or take it to an independent shop.

That's the issue, I have read horror stories trying to take the cv axles off and there's a possibility the short shaft inside the front differential might need to be replaced as well. I guess this is the reason Ram identifies this as unserviceable from what I understand. And if I had to replace the cv axles I'd probably go with trakmotive's extended axles for better compatibility with a lift kit.

 

[Wnghks701]

That's the issue, I have read horror stories trying to take the cv axles off and there's a possibility the short shaft inside the front differential might need to be replaced as well. I guess this is the reason Ram identifies this as unserviceable from what I understand. And if I had to replace the cv axles I'd probably go with trakmotive's extended axles for better compatibility with a lift kit.

Alright. Update!

Dealership is replacing both axle shafts under extended warranty. They said intermediate shafts are good. Hopefully they are not rusted to a point where they can’t get it out. I assume they are not if they were able to inspect intermediate shaft.